Catalytic treatment of hydrocarbon oils



Aug. 3, 1943. G. M. KERANEN CATALYTIC TREATMENT OF HYDROGARBON OILS 2 sheets-sheet '1 Filed Dec. 23

All@ 3, 1943. G. M. KERANEN 325,511

CATALYTIC TREATMENT OF HYDROCARBON OILS Filed DBC. 25, 1940 2 Sheets-Sheet 2 da T 99 1 w CLASS/EVER PHL MEE/ZEE Patented Aug. 3, 1943' cATALY'rIc TREATMENT or mnocmon oms y George M. Kennen, Homewood, lll., assigner tol -Standard Oil Company,-

ration of Indiana 'Application December 23,

Claims.

This invention relates to the process of treatingA or converting hydrocarbon oils with catalysts in powdered form and the invention relates more particularly to the cracking of heavy hydrocarbon oils to produce motor fuels of the character of gasoline. The invention also relates to the catalytic treatment of naphthas and gasoline of low knock rating to increase the knock rating .of these stocks.

One object of the invention is to obtain a more efllcie'nt utilization of the catalyst in the powdered catalyst conversion process than has heretofore been obtainable. Another object of the invention is to provide a method for simultaneously employing catalyst of both ne and coarse state of subdivision without sacrificing the catalytic eiectiveness of either the ilne or the coarse catalyst. Still another object of the invention is to provide va method for systematically discarding from the conversion system that part of the catalyst which is most nearly exhausted and retaining within the system that part of the catalyst which is most recently admitted thereto and which has undergone a minimum degradation. Other objects of the invention will become apparent from the following description thereof. 'I'he invention is illustrated by drawings which form a part of this specication in which Figure l 1 shows a diagrammatic elevation of an apparatusA suitable for carrying out the process and Figure 2 shows another diagrammatic elevation of a modi- Chicago, lll., a corpoisio, sen-h1 No. .211,221

(ci. lesa-52) reactor yat lor near the same velocity as would 4 occur in,` the case of horizontal reactors or yin the case where the vcatalyst travelled faster than the vapors. as in downiiow reactors.

One difficulty withthereactor employing retarded settling, however, lay in the fact that the y time of contact (catalyst residence time) between the hydrocarbon vapors and large and small cata- 'lyst particles could not be separately controlled as is desirable to compensate for the greater surface of the line catalystwhich leads to more rapid exhaustion. In order to avoid this dimculty, it `has frequently been necessary to lemploycatalysts of relatively uniform particle size and this has necessitated charging the process with a more expensive catalyst than would haveV been the case where powdered lcatalyst of 1indiscriminate ed apparatus employing a single regenerator for i both fine and coarse catalyst and also providing a classifier for eliminating from the system catalyst which is coarser than desired.

In the conversion of hydrocarbon loil using .powdered catalysts, itv has heretofore been the practice to vaporize the oil, heat the vapors to the desired elevated conversion temperature and mix with the vapors the desired amount of catalyst, forexample, about 1 to 10 parts of catalyst per part of oil. In order to increase the time of contact between catalyst particles and oil vapors. the vapors and dispersed catalyst have been introduced near the bottom of an elongated vertical reaction tower in which the vapor velocitiesl were held sufiiciently low to permit relative settling or sedimentation of the catalystfin the tower with respect to the vapor stream. In this manner the catalyst was retained in the reactor for a longer period of time than were the vapors and thus a more complete utilization of the catalyst was obtainable in a given volume of reaction space than would have been obtained had the catalyst and oil vapors been passed through the particle size was used.

Powdered catalysts commonly range from particles of about mesh downward to 400 mesh and nner, although sometimes catalysts of 30-40 mesh are classed as powdered. Excessively iine catalyst is generally undesirable because of the diiculty of retaining it in the system, recovering it from the spent reaction gases and regeneration gases, etc. Consequently, the tendency has been to avoid, as faras possible, those methods oi' handling the catalysts which result in the breakf down of particles. In prior processes employing powdered catalysts, there has also been the problem of eliminating the catalyst from the system when its efilciency hasfallen to an uneconomical point. In order to obtain satisfactory economy in operation, it is generally necessary to regenerate and recycle the catalyst many times in the process before it may be discarded. Consequently, when` fresh catalyst is added to the system at intervals to maintain catalyst eiiiciency, it has been substantially impossible to avoid discarding some relatively fresh catalyst along with the spent catalyst. In my process, however, I avoid this diiculty by charging to the system only coarse catalyst and discharging from the system only the fine catalyst segregated in the system.

According to my process, I employ catalyst of indiscriminate particle size, generally much coarser than previously employed, and, I effect a segregation of the coarse catalyst from the ne catalyst in various parts of the conversion system. 'I'he coarse catalyst is also contacted with the hydrocarbon vapors under diilerent conditions from those applied to the ne catalyst, thereby obtaining more emcient use of both coarse and line catalyst.

My process can be applied to variousl hydrocarbon conversion processes such as cracking heavier oils to gasoline, reforming low knock :rating gasoline' and naphthas such as straight-run naphtha, aromatization in the presence of hydrogen, etc. It will bedescribed as it is applied to cracking.

Referring to Figure 1 of the drawings, the

charging oil may be a typical distillate gas oil, for example, having a boiling range of about 425 to 750 F., lwhich is charged by line III to heater II where the oil is vaporized and heated to the desired conversion temperature, for example, 850 to 1050 F. The vapors are conducted by transfer line I2 to a p'oint near the bottom oi' reaction chamber I3. Before entering the reaction chamber,ne powdered catalyst is admitted to the hydrocarbon vapor stream from fine catalyst supply hopper I4, the catalyst dowing through line I5 and being conveyed to the reactor I3 by'a current of inert gas or steam introduced by line I6 or by the vapors in line I2.

Reaction chamber I3 is constructed with sufcient volume to provide the desired time of reaction between the fine catalyst particles and the vapor'stream. The reaction time required for properlutilization of the very i'lne catalyst may be about 1 to 10 seconds, more or less, depending largely on the nature of the catalyst employed. For example, the reaction. time may be 1/2 to 2 seconds. The time in which the iine catalyst is in contact-with the hydrocarbons (catalyst residence time) will be substantially the time required for the oil vapors to pass through the reaction chamber because of the very low settling or sedimentation rate of the fine catalyst employed. The ne catalyst dispersed in the oil vapors, after leaving chamber I3, is conducted by line I1 to av suitable catalyst separator such as cyclone separator I8 where the catalyst is separated from the vapors and the vapors are conducted by line. I9 to suitable fractionating apparatus 20 from which the gasoline vapors are withdrawn by line 2l leading to separator 22. Oil heavier than the desired gasoline is withdrawn from the base of fractionator 20 by line 23 which may conduct it to a, fuel oil reservoir. Gasoline collected in separator 22 may be withdrawn by line 24 leading to a. suitable gasoline storage. Hydrocarbon gases and inert'gases produced in or contaminating the system are withdrawn by vent line 25. f

Returning now to reaction chamber I3, there is also` introduced a second supply of catalyst from catalyst hopper 26. A small amount of steam may be introduced by line 21 to assist in obtaining rapid dispersion of the catalyst in the upper part of reaction chamber I3.

The catalyst supplied from 26 is very considerably coarser than that supplied from I4. A

range of particle sizes from about 4 to 15y or 25 mesh may be employed, depending on vapor velocity in the reactor and other factors. Substantially all of the catalyst introduced by line 21 will sediment or settle downwardly through reactor I3 countercurrent to the upflowing hydrocarbon vapors. At the bottom of reactor I3 the coarser catalyst is collected and withdrawn by line 28 from which the catalyst is conveyed by line 29 to the regenerator. An inert gas such as nitrogen or flue gas may be employed for conveylngthe catalyst to the regenerator and in catalyst pressure tower 3|. 'I'his tower is sufficiently high to provide a head for the catalyst therein and enable it to be withdrawn from the base of the tower under a moderate pressure, sufcient to pass it through the regeneratorA and maintain it in uid condition. In order to keep the catalyst free iiowing iii 3| a stream of inert gas may be introduced by line 32, for the purpose of aerating the catalyst powder, the gas escaping by line 33. Other means of'f'circulating catalyst, such as a screw pump,'impe1ler, etc. may be used.

From tower 3| the catalyst is led at a controlled rate by line 34 to regenerator 35. Air or other oxygen-containing gas may be introduced by line 34a as a conveying medium or carrier gas. An additional oxidizing gas, for example, air, may be introduced as a regeneration gas by line 35a, thereby maintaining an oxidizing atmosphere Within the regenerator 35. A sufficiently high temperature is maintained within 35 to insure substantially complete combustion of the carbon containedv on the catalyst particles. Excessive heating, however, must be avoided otherwise permanent loss of catalyst activity will result especially in the case of certain catalystssuch as magnesia catalysts which have a relatively low temperature susceptibility, In general, the temperature of 'regenerator 35 may be about 950` to 1200 F. Higher temperatures resulting from the combustion of carbonaceous matter on the catalyst may be avoided in several ways, for example, by recycling regeneration gases through the regenerator or by introducing a cooling coil 36 as indicated in the' drawings.

The regenerated catalyst is conducted by line 3l to cyclone separator 38 wherein it Ais separated from the regeneration gases. The separated catalyst is allowed to fall into regenerated catalyst tower 39 whichr is similar in general design to tower 3l. A high column of catalyst is maintained in free-flowing condition therein by aeration gas admitted by line 4U and discharged by line 4I. A pump may also be used for this purpose.

The pressure available at the base of tower 39 is a summation of the catalyst head within 39 and the pressure of separator 38 from which the catalyst is discharged into the tower. I may maintain a moderate pressure within separator 38 by means of automatic valve 42 and substantially the same pressure will be held in regenerator 35. Certain advantages result from maintaining the tower under pressure, particularly the` advantage of better temperature control because of the higher volumetric heat capacity of the regeneration gases when employed under pressure. The amount of pressure maintained in regenerator 35 and separator 38 may be of the order of 5 to 15 pounds per square inch, As a result of feeding the tower 39 by catalyst under pressure, I do not need to employ catalyst towers as high as would otherwise be the case.

From catalyst tower 39, the catalyst is conveyed by line 43 back to the reaction step of the process. The catalyst may be conveyed by a carrier gas introduced at 44, and the gas separated from the catalyst again in coarse catalyst supply hop- Fresh catalyst may be added .to the.

generator 35 and catalyst tower 39.

Now we will consider the ilow ot the nne vcatilyst in the system. The fine catalyst which is separated from the converted hydrocarbon var` 'pors in cyclone I! passes into catalyst tower 4B,

`. in case of air. some regeneration is effected. Air

or other regeneration gas is introduced by line $2 into the base of regenerator lil and combus- -tion of carbonaceous deposits is carried out in regenerator il under controlled conditions, somewhat the same as .the conditions prevailing in regenerator 3B. vRegulation of the temperature may be assisted by cooling coil it. Because of the nner character of the catalyst in l0, however, somewhat lower concentrations of oxygen may be employed in the regeneration gases for eecting complete regeneration.

From the regenerator lll the catalyst is conducted in a stream of regeneration gases by line ll to cyclone separator 5l where the catalyst is separated from the regeneration gases, the latter being discharged fromthe system through vent 56. Superatmospheric pressure lmay be maintained in cyclone separator 55 and regenerator 5,0 by automatic relief valve 51 placed in vent 58, thereby facilitating regeneration of the catalyst in 50 and also permitting the catalyst to be discharged from cyclone l5 undei` a pressure in a manner similar to the operation of cyclone 38 hereinabove described.

'I'he separated line catalyst ilows from cyclone 5I into catalyst tower 58 where suillcient head of catalyst is maintained to set up at the bottom of the tower suiilcient -pressure for recycling to the conversion system. The catalyst in 58 is maintained in iluid condition by continuously or in- At higher vapor velocities in Il relatively more of the coarser catalyst will be carried over through line I1 and thence into the ne catalyst recycle system whereas at lower vapor velocities relatively more of the fine catalyst will be permitted to settle in reaction chamber Il and ilow therefrom through line 29 into the coarse recycle system. In the operation of myprocess, therefore, I aim to maintain the conditions within reactor il relatively constant especially with respect to vapor velocity, thereby effecting a relatively uniform division between coarse and ilne catalyst therein. Therefore, the amount of catalyst withdrawn atl I'l and 2E respectively may be equal or may be adjusted to almost any desired ratio, `for example, from 2 to' 5 times as much catalyst may be withdrawn through line I1 as through line 29 or vice versa, depending on the vapor velocities inrreactor `lf3 and distribution of i particle size of the catalyst.

The particle size of they coarse catalyst-will ordinarily be `within the range of about 4 to 50 mesh. depending on velocity conditions, whereas the ne catalyst will have a particle size generally within the -range of about 15 to 200A and up to 400 mesh and ilner, again depending on vapor velocity in the reactor. As indicated hereinabove, however, this division -of particle size may be altered very considerably, depending on operating conditions.

In the case where high velocities are employed in the reaction zone, the conditions of hindered settling of catalyst particles therein becomes less important than at low velocities and as a result classiilcation of coarse and ne catalyst becomes Y more eiective. At the higher velocities, therefore, I may introduce at the top of the reactor a catalyst having somewhat smaller particle size .25 feet per second or as high as 40 feet per sec-` termittently introducing aeration gas throughline 59 discharging through line Sii. Y

From tower 58 the catalyst ilows by line 8| to catalyst supply drum Il previously described. To assist in conveying the catalyst through line 6I carrier gas may be introduced by line 82 and separated at the vent in supply drum Il.

In ordinary practice, the amount of catalyst lost with regeneration gases through vents 42 and 51 is suillcient to permit new catalyst to be added to the system at 45 at a rate sumcient to maintain catalyst activity at the desired point. Where a higher level of catalyst activity is desired, however, this may be obtained by discharging the tine catalyst at any desired rate through discharge line 63. Some catalyst is generally lost from theV system in the gases passing through line I9 to fractionator 20, this material being collected as a slurry in the reilux from the fractionator and discharged by line 2l with thefuel oil. If desired, it may be recovered by illtration or settling and returned to the system.

I have referred hereinabove to thecatalyst in recycle lines I3 and 6I as coarse and fine respectively and these terms are employed with than when employing low vapor velocities in the reactor. Thus, at vapor velocities of about l5 to ond, the coarse catalyst introduced at the top of the reactor may be about 10 to 30 mesh or even 50 mesh and simultaneously under these conditions the fine catalyst may have a particle size of about 40 toZO mesh or finer, e. g., 300 to 400 mesh. Some overlapping of particle size inevitably results.

Where the vapor velocities are lower, for example, of the order of 3 to 10 feet per second, and .up to 15 feet per second, I may introduce at the top of the reactor a catalyst with particle size of 4 to 10 mesh or even 15 mesh while the fine catalyst will be essentially the same as previously, including somewhat coarser material of the order of 15 to 25 mesh. These numerical values are given by way of example and do not limit the scope of my invention which involves broadly the process of counterilowing catalyst of fine and coarse grade in a single upilow reaction chamber.

Referring to `Figure 2 the charge oilis .admitted at 10 and is vaporized and heatedin heater 1l, the vapors then passing by line 12 into the base of reactor 13. 'Fine catalyst may be introl duced into the vapor line 'l2 where it is dispersed in the vapors and travels with them upwards throughout the length of the reactor. v A part or all of the fine catalyst may be introduced by line 1l at an intermediatepoint in the reactor 1,3, if desired. It is usually advantageous to have steam present in the reaction and a current of steam may be used conveniently for injecting the powderedcatalystystream, the steam being admitted by line 15. withdrawn from supply reservoir 16.

The ilne catalyst may be Coarse catalyst is introduced' at the top o1' reactor 13 by line 4'I1 leading from coarse catalyst supply 18. Thecoarse catalyst falls through reactor i3 countercurrent to the rising hydrocarbon vapors therein and is withdrawn from the reactor by line 19'which conveys it to cyclone separator 80. A carrier gas may be introduced at 8i to facilitate catalyst now through 79, or .a pump or other means maybe used for catalyst transfer.

The converted vapors of hydrocarbon with suspended fine catalyst are withdrawn at the top of reactor'13 by line 82 leading to cycloneseparator di) wherein both line and coarse catalyst are separated from the vapors, the oil vapors passing by line 83 to fractionator and gasoline recovery system not shown but arranged similar to that f Figure 1.

The coarse and fine catalyst together flow from cyclone 8|) into the top of catalyst tower 8l where it is maintained in a fluid condition by aerating Y gas introduced at 85 and discharged at 86. The catalyst is withdrawn at the base of' 84 under superatmospheric pressure generally of to 30 pounds per square inch and thence by line 81 to` regenerator 88. Air may be introduced at 89 into line S'I'as a carrier gas and to initiate regeneraa tion of the catalyst by combustion of carbonaceous deposits. Additional regeneration gas is introduced into 88 byline 98. Excess heat of regeneration may be removed from regenerator 88 by cooling coil 9| or by recycling regenerated be obtainedvin regenerator 88. This may be accomplished readily by controlling the vapor velocities in 88, for example, by recycling spent regeneration gas therein.

Fron'i regenerator 88 the spent regeneration gases carrying fine catalyst pass by line 92 to cyclone separator 93 where spent regeneration gases are eliminated by vent 94. Fine catalyst il'ows from separator 93 into catalyst standpipe 85 Where it is maintained in a fluid condition by suitable aeration gas introduced at 96 and eliminated at 91. From the base of catalyst tower 95 the catalyst is conducted by line 98, if desired with the aid of carrier gas introduced at 98a back .to fine catalyst supply 'I6 from where it re-enters the hydrocarbon conversion system previously described.

From the base of regenerator 88 the coarse.

catalyst is withdrawn by line 99, if desired, with the aid of carrier gas introducedat |00, back to coarse catalyst supply reservoir 18. fresh catalyst may be introduced into the system at Ill|,-the particle size of the catalyst being selected to be about vthe same as the coarse catalyst recycled in the system. As the catalystis recycled,.it becomes iiner and finer due to unavoidable attrition in the system and eventually it reaches a state of subdivision of sufficient fineness 'to-escape the usual recovery means such as cyclone separators or electrostatic precipitators.

lThis very ne catalyst is continually lost from the system-mostly through vapor line 83 and regenerator gas vent 94; However, by continually supplying catalyst to the system in the coarse state, that catalyst which is lost from the system Makeup than desired, leading to erosion 'of equipment and other dimculties. In order to prevent the accumulation or agglomerates in the system, I may bypass a part or all of the coarse catalyst from.`

recycle line 99 through line G82 into classifier tot where any agglomerates coarser than desired in the coarse catalyst recycle system are screened out or separated by other means and are conducted by lineitd to pulverizer itt and thence by lines E08 land 88 to the nne catalystfsupply it. Carrier gas may be introduced at im if desired. The properly graded coarse catalyst from classifier w3 may be conducted by line it'and line,l 88 to the coarse catalyst supply llt.

Instead of using a combination regenerator and classifier as described for 88, I may employ a suit'- able high velocity upfiow regenerator in which all the catalyst, both fine and coarse, is introduced near the bottom and carried out the top to two cyclone separators connected in series, the coarse catalyst being segregated in the first cyclone separator and the ilne catalyst in the second. Coarse and ne catalyst may then be recycled in the system through effective repressuring means such as catalyst standpipe towers, one for the coarse and one for the fine.` This arrangement is an obvious modification of the design shown in Figure 2 and is not described in the drawings.

The catalysts I employ are the refractory, solid oxides of various metals, usually a mixture of two or more oxides such as silica and alumina, silica. and magnesia, and oxides of metals `of groups V and VI. Silica. gel or other active silica may be promoted with active alumina, magnesia, beryllia, etc. Molybdena or chromia may be used on alumina. Clays, fullers earth, bentonite, etc. may be activated by acid and form especially good cracking catalysts.

Having thus described my invention` what I clarn is:

1. The process of treating hydrocarbon oils with a powdered catalyst, comprising employing a catalyst having a widerange -of particle size, contacting hydrocarbon vapors at conversion temperatures with said` catalyst in a vertical, elongated reaction zone, introducing the nder constituents of said catalyst with said vapors near the bottom of said reaction zone, introducing the coarser constituents of said catalyst near the top of said reaction zone, `flowing said hydrocarbon vapors upwardly through said reaction zone, regulating the velocity of said vapor flow to permit settling said coarse catalyst countercurrent to said vapors, withdrawing said vapors and iine catalyst dispersed therein from the top of said reaction zone, withdrawing coarse catalyst from the bottom of said reaction zone, separating the catalyst from treated hydrocarbon vapors, regenerating said coarse and ine catalyst by controlled combustion with oxygen-containing gas to' remove carbonaceous deposists, recycling coarse catalyst tothe top of said reaction zone and recycling said ne catalyst to the hydrocarbon vapors nearthe bottom of said reaction zone.

2. The process of claim 1 wherein coarse and fine catalyst streams are separately regenerated.

l3. The process of claim 1 wherein coarse and fine catalyst streams withdrawn from said reaction zone are united, simultaneously regenerated and then reclassified before recycling to said reaction zone. t

4. The process of yconverting hydrocarbon oils by the action of powdered catalysts comprising heating and vaporizing said oils and passing the vapors thereof upwardly through an elongated, vertical reaction zone, introducing coarsely powdered solid conversion catalyst at an elevated point in said reaction zone, introducing finely` powdered solid conversion catalyst at the lower part of said reaction zone and dispersing it in said hydrocarbon vapors, maintaining the velocity of said vapors below thesettling rate of said coarsely powdered catalyst and above the settling rate'of the said finely powdered catalyst,

' whereby the ne catalyst is carried through said reaction zone in suspension in said vapors effecting concurrent conversion thereof simultaneously with countercurrent contacting of said the tower, regenerating the catalyst under pressure substantially equal to said hydrostatic pressure, without releasing pressure, separating the catalyst; from regeneration gases and charging the regenerated catalyst to a second catalyst tower at a pressure substantially equal to the pressure of said regenerator and withdrawing and recycling catalyst from the base of said second tower at a pressure substantially equal to the combined hydrostatic pressures of said towers.

8. In the process of converting hydrocarbon oils into gasoline of high knock rating wherein the vapors of said oils are contacted at an elevated temperature with a mixture of coarse and flne powdered catalyst maintained in suspension, the coarse catalyst flowing countercurrently to the vapors and the fine catalyst flowing concurrently with the vapors and wherein the catalyst is separated from said hydrocarbon vapors, re-

vapors by said coarse catalyst descending through said reaction zone, withdrawing catalyst and hydrocarbon vapors from said reaction zone and separating the spent catalyst from said hydrocarbons, fractionating said hydrocarbons to rei cover high knock rating gasoline therefrom, re-

generating said separated catalyst by controlled combustion with oxygen-containin'ggases whereby carbonaceous deposits are removed and recycling the regenerated catalyst to said reaction Zone.

5. The process of claim 4 wherein the mixture of saidspent catalyst is charged to an intermediate point in a vertical, elongated regeneration zone and regeneration gases are passed upwardly through said regeneration zone at a velocity intermediate between the settling` rate of coarse catalyst and fine catalyst, thereby permitting coarse catalyst to settle to the bottom of saldregeneration zone and flne catalyst to be carried by said regeneration gases to the top of said regeneration zone, separating the regeneration gases from said regenerated catalyst and recycling the regenerated coarse catalyst and ine catalyst back to said reaction zone. v

6. The process of claim 4 wherein the spent coarse and tlne catalyst is combined and regenerated in a single regeneration zone by the action of oxygen-containing gases under conditions of controlled combustion. regenerated catalyst is graded into a coarsel and 'a ine grade and the grading is controlled to adjust the particle size of said coarse and ne grades of catalyst to be substantially the same. respectively, as the said coarse and ne catalyst charged to said reaction zone.

1. In the process of converting hydrocarbon oils by contacting the vapors at elevated conversion temperature with dispersed powdered solid4 catalyst and thereafter separating thecatalyst from the hydrocarbon vapors and regenerating the spent catalyst by'controlled combustion with oxygen-containing gases, after which the catalyst is recycled in the process, the method of recycling the catalyst which comprises establishing pressure on said catalyst by charging it to the top of a tower lled with catalyst and withdrawing it from the bottom of said tower under a pressure equal. to the hydrostatic pressure of catalyst in generated by controlled combustion with oxidizing gases and the regenerated catalyst is recycled to the conversion zone, the improvement comprising maintaining the eiliciency of said catalyst by continually discarding from the system part of said nely divided catalyst and continually 4adding an equivalent amount of fresh coarse catalyst to the system, the supply of fine catalyst in the system being replenished by disintegration of coarse catalyst.`

9. In the process of converting hydrocarbon oils into gasoline of high knock rating by the action of subdivided solid catalysts comprising both coarsely divided and finely divided catalysts, wherein the hydrocarbon vapors are contacted with said catalysts in suspension at elevated conversion temperature, and the catalysts are separated from the converted hydrocarbons, the method of extending the time of contact of said hydrocarbons with said coarsely divided catalysts beyond that of said nely divided catalyst by countercurrently contacting the hydrocarbon vapors with said coarsely divided catalyst and concurrently contacting said vapors with said finely divided catalyst simultaneously in a single vertically disposed reaction zone through which said vapors are passed in an upward direction at a velocity suillcient to prevent the separation of ne catalyst from said vapors while permitting said coarse catalyst to settle to the bottom of said zone whence it may be separately withdrawn, said ne catalyst being introduced into said reaction zone at an intermediate point thereof. i 10. In the process of converting hydrocarbon oils into high knock rating gasoline by contacting the vapors of said oils at elevated conversion temperatures with a solid. powderedconversion catalyst, separating the catalyst from the converted hydrocarbon vapors, regenerating the sepw arated catalyst and recycling it in the system,

the improvement comprising employing a catalyst consisting of coarse and fine grades, separately charging both grades of catalyst to the lsaid contacting step simultaneously, separating agglomerated catalyst formed in the system from the coarse grade and pulverizing it to a. size substantially equivalent to the fine grade and returning it to the system.

GEORGE M. mam. 

